Patents Assigned to Natcore Technology Inc.
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Patent number: 10453976Abstract: A solar cell structure may provide a front surface that may include a front passivation layer and front anti-reflective layer. The solar cell structure may provide both contacts on a rear surface. In some cases, the rear surface may optionally provide passivation, doped, and/or transparent conductive oxide layers. The rear surface also provides a multilayer foil assembly (MFA). The MFA provides a first metal foil in electrical communication with doped regions of the rear surface of the substrate, such as base or emitter regions. The MFA may also provide a second metal foil that is spaced apart from the first metal foil by a dielectric layer. The metal foils and dielectric layers may include openings through the entirety of these layers, and these openings may be utilized to form contacts electrically coupled to the second metal foil, which is electrically isolated from the first metal foil.Type: GrantFiled: June 19, 2018Date of Patent: October 22, 2019Assignee: NATCORE TECHNOLOGY, INC.Inventors: David E. Carlson, David Howard Levy
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Patent number: 10290750Abstract: A solar cell structure may provide a front surface that may include a front passivation layer and front anti-reflective layer. The solar cell structure may provide both contacts on a rear surface. In some cases, the rear surface may optionally provide passivation, doped, and/or transparent conductive oxide layers. The rear surface also provides a multilayer foil assembly (MFA). The MFA provides a first metal foil in electrical communication with doped regions of the rear surface of the substrate, such as base or emitter regions. The MFA may also provide a second metal foil that is spaced apart from the first metal foil by a dielectric layer. The first metal foil and/or the dielectric layer may include openings through the entirety of these layers, and these openings may be utilized to form laser fired contacts electrically coupled to the second metal foil, which is electrically isolated from the first metal foil.Type: GrantFiled: August 26, 2016Date of Patent: May 14, 2019Assignee: Natcore Technology, Inc.Inventors: David E. Carlson, David Howard Levy
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Publication number: 20180366597Abstract: A solar cell structure may provide a front surface that may include a front passivation layer and front anti-reflective layer. The solar cell structure may provide both contacts on a rear surface. In some cases, the rear surface may optionally provide passivation, doped, and/or transparent conductive oxide layers. The rear surface also provides a multilayer foil assembly (MFA). The MFA provides a first metal foil in electrical communication with doped regions of the rear surface of the substrate, such as base or emitter regions. The MFA may also provide a second metal foil that is spaced apart from the first metal foil by a dielectric layer. The metal foils and dielectric layers may include openings through the entirety of these layers, and these openings may be utilized to form contacts electrically coupled to the second metal foil, which is electrically isolated from the first metal foil.Type: ApplicationFiled: June 19, 2018Publication date: December 20, 2018Applicant: Natcore Technology, Inc.Inventors: David E. Carlson, David Howard Levy
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Patent number: 9837561Abstract: An interdigitated solar cell may provide a heterojunction or tunnel junction emitter and base contacts that comprise laser processed regions that electrically couple the base contact to a substrate. Methods for manufacturing such solar cells to provide interdigitated back contacts may utilize laser processing to form laser processed regions that are isolated from the emitter. Laser processing may include laser-doping, laser-firing, laser-transfer, laser-transfer doping, laser contacting, and/or gas immersion laser doping.Type: GrantFiled: March 14, 2016Date of Patent: December 5, 2017Assignee: Natcore Technology, Inc.Inventors: David Howard Levy, David E. Carlson
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Patent number: 9825199Abstract: A laser processing system can be utilized to produce high-performance interdigitated back contact (IBC) solar cells. The laser processing system can be utilized to ablate, transfer material, and/or laser-dope or laser fire contacts. Laser ablation can be utilized to remove and pattern openings in a passivated or emitter layer. Laser transferring may then be utilized to transfer dopant and/or contact materials to the patterned openings, thereby forming an interdigitated finger pattern. The laser processing system may also be utilized to plate a conductive material on top of the transferred dopant or contact materials.Type: GrantFiled: December 28, 2016Date of Patent: November 21, 2017Assignee: NATCORE TECHNOLOGY, INC.Inventor: David E. Carlson
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Publication number: 20170110623Abstract: A laser processing system can be utilized to produce high-performance interdigitated back contact (IBC) solar cells. The laser processing system can be utilized to ablate, transfer material, and/or laser-dope or laser fire contacts. Laser ablation can be utilized to remove and pattern openings in a passivated or emitter layer. Laser transferring may then be utilized to transfer dopant and/or contact materials to the patterned openings, thereby forming an interdigitated finger pattern. The laser processing system may also be utilized to plate a conductive material on top of the transferred dopant or contact materials.Type: ApplicationFiled: December 28, 2016Publication date: April 20, 2017Applicant: Natcore Technology, Inc.Inventor: David E. Carlson
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Publication number: 20170062633Abstract: A solar cell structure may provide a front surface that may include a front passivation layer and front anti-reflective layer. The solar cell structure may provide both contacts on a rear surface. In some cases, the rear surface may optionally provide passivation, doped, and/or transparent conductive oxide layers. The rear surface also provides a multilayer foil assembly (MFA). The MFA provides a first metal foil in electrical communication with doped regions of the rear surface of the substrate, such as base or emitter regions. The MFA may also provide a second metal foil that is spaced apart from the first metal foil by a dielectric layer. The first metal foil and/or the dielectric layer may include openings through the entirety of these layers, and these openings may be utilized to form laser fired contacts electrically coupled to the second metal foil, which is electrically isolated from the first metal foil.Type: ApplicationFiled: August 26, 2016Publication date: March 2, 2017Applicant: Natcore Technology, Inc.Inventors: David E. Carlson, David Howard Levy
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Patent number: 9570638Abstract: A laser processing system can be utilized to produce high-performance interdigitated back contact (IBC) solar cells. The laser processing system can be utilized to ablate, transfer material, and/or laser-dope or laser fire contacts. Laser ablation can be utilized to remove and pattern openings in a passivated or emitter layer. Laser transferring may then be utilized to transfer dopant and/or contact materials to the patterned openings, thereby forming an interdigitated finger pattern. The laser processing system may also be utilized to plate a conductive material on top of the transferred dopant or contact materials.Type: GrantFiled: July 15, 2015Date of Patent: February 14, 2017Assignee: NATCORE TECHNOLOGY, INC.Inventor: David E. Carlson
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Patent number: 9449824Abstract: A method for an improved doping process allows for improved control of doping concentrations on a substrate. The method may comprise printing a polymeric material on a substrate in a desired pattern; and depositing a barrier layer on the substrate with a liquid phase deposition process, wherein a pattern of the barrier layer is defined by the polymeric material. The method further comprises removing the polymeric material, and doping the substrate. The barrier layer substantially prevents or reduces doping of the substrate to allow patterned doping regions to be formed on the substrate. The method can be repeated to allow additional doping regions to be formed on the substrate.Type: GrantFiled: April 24, 2014Date of Patent: September 20, 2016Assignee: Natcore Technology, Inc.Inventors: David H. Levy, Daniele Margadonna, Dennis Flood, Wendy G. Ahearn, Richard W. Topel, Jr., Theodore Zubil
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Publication number: 20160268455Abstract: An interdigitated solar cell may provide a heterojunction or tunnel junction emitter and base contacts that comprise laser processed regions that electrically couple the base contact to a substrate. Methods for manufacturing such solar cells to provide interdigitated back contacts may utilize laser processing to form laser processed regions that are isolated from the emitter. Laser processing may include laser-doping, laser-firing, laser-transfer, laser-transfer doping, laser contacting, and/or gas immersion laser doping.Type: ApplicationFiled: March 14, 2016Publication date: September 15, 2016Applicant: Natcore Technology, Inc.Inventors: David Howard Levy, David E. Carlson
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Publication number: 20160163652Abstract: The present invention relates to coated fullerenes comprising a layer of at least one inorganic material covering at least a portion of at least one surface of a fullerene and methods for making. The present invention further relates to composites comprising the coated fullerenes of the present invention and further comprising polymers, ceramics, and/or inorganic oxides. A coated fullerene interconnect device where at least two fullerenes are contacting each other to form a spontaneous interconnect is also disclosed as well as methods of making. In addition, dielectric films comprising the coated fullerenes of the present invention and methods of making are further disclosed.Type: ApplicationFiled: February 12, 2016Publication date: June 9, 2016Applicants: William Marsh Rice University, Natcore Technology, Inc.Inventors: Andrew R. Barron, Dennis J. Flood, Elizabeth Whitsitt
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Patent number: 9324899Abstract: In some cases, it is desirable to perform doping when manufacturing a solar cell to improve efficiency. Dopant diffusion may include the steps of: (a) an initial temperature ramp, (b) dopant vapor flow, (c) drive-in, and (d) cool down. However, doping may result in excessive doping, such as in regions where the solar cell has been nanoscale textured to provide black silicon, thereby creating a dead zone with excessive recombination of charge carriers. In the systems and method discussed herein, dopant vapor flow and drive-in steps may be performed at two different temperature set points to minimize or eliminate the formation of dead zones. In some embodiments, the dopant vapor flow may be performed at a lower temperature set point than the drive-in.Type: GrantFiled: June 9, 2015Date of Patent: April 26, 2016Assignee: Natcore Technology, Inc.Inventors: Wendy G. Ahearn, David Howard Levy, Richard W. Topel, Jr., Theodore Zubil
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Patent number: 9306094Abstract: Systems and methods for etching the surface of a substrate may utilize a thin layer of fluid to etch a substrate for improved anti-reflective properties. The substrate may be secured with a holding fixture that is capable of positioning the substrate. A fluid comprising an acid and an oxidizer for etching may be prepared, which may optionally include a metal catalyst. An amount of fluid necessary to form a thin layer contacting the surface of the substrate to be etched may be dispensed. The fluid may be spread into the thin layer utilizing a tray that the substrate is dipped into, a plate that is placed near the surface of the substrate to be etched, or a spray or coating device.Type: GrantFiled: August 25, 2014Date of Patent: April 5, 2016Assignee: Natcore Technology, Inc.Inventors: David Howard Levy, Theodore Zubil, Richard W. Topel, Jr., Wendy G. Ahearn
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Patent number: 9290665Abstract: The present invention relates to coated fullerenes comprising a layer of at least one inorganic material covering at least a portion of at least one surface of a fullerene and methods for making. The present invention further relates to composites comprising the coated fullerenes of the present invention and further comprising polymers, ceramics, and/or inorganic oxides. A coated fullerene interconnect device where at least two fullerenes are contacting each other to form a spontaneous interconnect is also disclosed as well as methods of making. In addition, dielectric films comprising the coated fullerenes of the present invention and methods of making are further disclosed.Type: GrantFiled: October 11, 2011Date of Patent: March 22, 2016Assignees: WILLIAM MARSH RICE UNIVERSITY, NATCORE TECHNOLOGY, INC.Inventors: Andrew R. Barron, Dennis J. Flood, Elizabeth Whitsitt
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Publication number: 20160020343Abstract: A laser processing system can be utilized to produce high-performance interdigitated back contact (IBC) solar cells. The laser processing system can be utilized to ablate, transfer material, and/or laser-dope or laser fire contacts. Laser ablation can be utilized to remove and pattern openings in a passivated or emitter layer. Laser transferring may then be utilized to transfer dopant and/or contact materials to the patterned openings, thereby forming an interdigitated finger pattern. The laser processing system may also be utilized to plate a conductive material on top of the transferred dopant or contact materials.Type: ApplicationFiled: July 15, 2015Publication date: January 21, 2016Applicant: Natcore Technology, Inc.Inventor: David E. Carlson
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Patent number: 9236509Abstract: Systems and methods for producing nanoscale textured low reflectivity surfaces may be utilized to fabricate solar cells. A substrate may be patterned with a resist prior to an etching process that produces a nanoscale texture on the surface of the substrate. Additionally, the substrate may be subjected to a dopant diffusion process. Prior to dopant diffusion, the substrate may be optionally subjected to liquid phase deposition to deposit a material that allows for patterned doping. The order of the nanoscale texture etching and dopant diffusion may be modified as desired to produce post-nano emitters or pre-nano emitters.Type: GrantFiled: April 24, 2014Date of Patent: January 12, 2016Assignee: Natcore Technology, Inc.Inventors: David H. Levy, Daniele Margadonna, Dennis Flood, Wendy G. Ahearn, Richard W. Topel, Jr., Theodore Zubil
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Publication number: 20150357506Abstract: In some cases, it is desirable to perform doping when manufacturing a solar cell to improve efficiency. Dopant diffusion may include the steps of: (a) an initial temperature ramp, (b) dopant vapor flow, (c) drive-in, and (d) cool down. However, doping may result in excessive doping, such as in regions where the solar cell has been nanoscale textured to provide black silicon, thereby creating a dead zone with excessive recombination of charge carriers. In the systems and method discussed herein, dopant vapor flow and drive-in steps may be performed at two different temperature set points to minimize or eliminate the formation of dead zones. In some embodiments, the dopant vapor flow may be performed at a lower temperature set point than the drive-in.Type: ApplicationFiled: June 9, 2015Publication date: December 10, 2015Applicant: Natcore Technology, Inc.Inventors: Wendy G. Ahearn, David Howard Levy, Richard W. Topel, JR., Theodore Zubil
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Patent number: 9169564Abstract: A rapid liquid phase deposition (LPD) process of coating a substrate provides improved deposition rates. The LPD process may include the following steps: incubation of acids with corresponding oxides, sulfide, or selenide for a predetermined period of time; removing the undissolved oxides, sulfide, or selenide; liquid phase deposition of the oxide, sulfide, or selenide film or coating at an elevated temperature; and removing the substrate from the growth solution. Further, the growth solution can be prepared for re-use by cooling to a desired temperature and adding extra oxides, sulfides, or selenides.Type: GrantFiled: February 14, 2012Date of Patent: October 27, 2015Assignee: NATCORE TECHNOLOGY, INC.Inventors: Oleg A. Kuznetsov, Yuanchang Zhang
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Patent number: 9093267Abstract: A deposition process for coating a substrate with films of varying thickness on a substrate can be achieved. The thickness of the film deposition can be controlled by the separation between the substrate and a curtain. Different separation distances between the substrate and curtain in the same chemical bath will result in different film thicknesses depositing on the substrate.Type: GrantFiled: March 14, 2014Date of Patent: July 28, 2015Assignee: NATCORE TECHNOLOGY, INC.Inventor: Yuanchang Zhang
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Publication number: 20150056818Abstract: Systems and methods for etching the surface of a substrate may utilize a thin layer of fluid to etch a substrate for improved anti-reflective properties. The substrate may be secured with a holding fixture that is capable of positioning the substrate. A fluid comprising an acid and an oxidizer for etching may be prepared, which may optionally include a metal catalyst. An amount of fluid necessary to form a thin layer contacting the surface of the substrate to be etched may be dispensed. The fluid may be spread into the thin layer utilizing a tray that the substrate is dipped into, a plate that is placed near the surface of the substrate to be etched, or a spray or coating device.Type: ApplicationFiled: August 25, 2014Publication date: February 26, 2015Applicant: Natcore Technology, Inc.Inventors: David Howard Levy, Theodore Zubil, Richard W. Topel, JR., Wendy G. Ahearn